AHMED ALTERKAIT Snr Eng, Manufacturing Excellence - KNPC

KNPC EFFORTS TOWARDS REDUCING HYDROCARBON LOSS & FLARE GAS MANAGEMENT Introduction. Challenges Efforts Made: Review the measurement methodology :

losses type, Source , measurement & breakdown Defining the uncertainties. reconciliation method & Correction factors

Conclusion

Introduction KNPC Operates highly complex Refineries.

Complex units & integration Thousands of valves flowmeters & analyzers More than 20 Elevated Flare Stacks

Current Capacity over 700,000 BPD

Challenges In 2015, High hydrocarbon loss (by balance) reported.

Refinery Loss ( loss by balance) = Refinery input – Refinery output – Fuels + (∆ Inventory).

The same was captured by SAB & raised in the

parliament.

Efforts Made committee formed to review accounting methodologies

& practices being followed. Defining the losses type, Source breakdown,

accounting Methodologies Defining the uncertainty reasons. Defining the correction factors

Finding :

Loss Types: Controllable loss : Losses that can be reduced to the bench mark levels based on the

refinery configuration.

Non-Controllable loss : Losses that is part of normal refinery operation ( i.e. side

products or side loss )

Finding:

Controllable Losses

Breakdown Measurement Method Reference

H/c loss through Flares (Ex H2) 13% Flowmeters Chevron feedback , International Standards

H/c loss to Bio-treatment

6%

Analysis + Calculation Newly Identified, IP Document Page 34

H/C in Sea Water effluent Analysis + Calculation Record Available , to be reported

API Evaporation & Process Fugitives Analysis + Calculation Records available, to be re-classified and reported as per the standards. IP Document Page 8

Hydrogen Venting Flowmeters Record Available. To be included in loss report for MAA & MAB

Finding:

Non-controllable Process Losses Breakdown Measurement Method Reference

Carbon loss as CO2 from HP Units 71% Mass Balance, part of production International Standard IP Doc Page 34 & Solomon Methodology

H2 loss as H2O from SRU Units

10%

Mass Balance, part of production

International Standard, IP Doc page 7 Record available to be reported.

Nitrogen Loss as NH3 Mass Balance, part of

production

International Standard IP Doc Page 34 No record for MAA & SHU.

FCC Coke Heat Balance Solomon Methodology

CCR Coke Heat Balance Newly Identified found in IP Document page 7

Flare Pilot & Purge Design figures Solomon Methodology

VOC Emissions analysis & calculations Solomon Methodology Hydrocarbon in dispatched Ash (WWT) / waste

analysis Newly Identified, found in IP document Page 9

Defining the uncertainty reasons Instrumentation errors

Test run to ensure instrumentation accuracy. Systematic error. Random error.

Non-hydrocarbon interference. Analyze the flared gas and deduct the purge gas

quantities and the non hydrocarbon gases. Zero value losses

Part of the refinery operation.

Reconciliation method & Obtaining Correction factors • Reconciliation method link

۱۳

Compressor Suction K.O.D

Drain

Passing PSV

Compressor Stuffing Box

Lines

Passing Control Valves

GT Passing Gas Traps

Flare header FG Purge

Passing Sample Point Purge

Passing v/v of De-Pressurizing lines

Passing pump casing vent

Reconciliation method & Obtaining Correction factors • Obtaining Correction factors

Lab analysis. Field survey. Link Mass Balance.

AccuTrack – a small hand-held device that measures the sound created by gases or liquids passing through an opening. V-Pac – a much more sophisticated device to measure sound. Can estimate quantity of passing. IR Camera – Multi-purpose tool that projects real-time picture showing temperature gradients.

http://home.knpc.net/../temp/VALVECP.AVI

Conclusion

81% of the refinery reported loss found to be zero value, wherein 71% due to CO2 venting from HPU.

Max Unaccountable Loss for MAA = 0.7% & MAB = 0.5%

Totally new sources of losses have been identified.

71

۱۰%

۱۳% ٦%

۱۹%

LOSS BY BALANCE BREAKDOWNS CO2 Other uncontrollables Flaring Other Controllables

Conclusion • H/C Loss Book Value reduced by 81 % • Improvement in physical HC Loss reported by Solomon since 2014 study.

KNPC are within the international companies practices. < 1%

KNPC reached the boundary for the first quartile for 2018 Solomon study

with hc loss of about 0.2X%.

THANK YOU

Slide Number 1Slide Number 2Slide Number 3KNPC EFFORTS TOWARDS REDUCING HYDROCARBON LOSS & FLARE GAS MANAGEMENTIntroductionChallengesEfforts MadeFinding : �Finding:�Finding: �Defining the uncertainty reasonsReconciliation method & Obtaining Correction factorsSlide Number 13Slide Number 14Reconciliation method & Obtaining Correction factorsSlide Number 16ConclusionConclusionSlide Number 19